In early October the Illinois Railway Museum was host to the annual convention of The Vintage Machinery group, Arnfest. Besides this being a chance for us to clean out a years worth of shop project leftovers, the Arnfest group generously repairs some of our old shop equipment.

This year besides replacing the bearings on our small band saw, they took on our big Fay and Eagan Jointer. The babbit bearings on this 100 plus year old machine were worn almost to the point of failure. Thanks to Tim, Victor, John and other shop regulars we were able to move it to a point to be worked on during the convention. The photos tell the rest of the story. (All photos from Buzz Morisette).

Interesting to anyone that walked past, the old tool Whatsit table was a place for interesting conversation.

Job one was to remove the jointer’s old babbit metal.

Torches were used to heat the bearing pockets for the lower pour.

Another shot showing how torches were used to heat the bearing pockets for the lower pour.

Monday, October 12. 2015

Warren Newhauser wrote the following summary of the recent work done on the X-5000:

Chuck Trabert moves a cable out of the way before the test begins - Photo by Warren Newhauser

On the morning of Wed. Oct 7, Chuck Trabert, Chuck Pomazal and Warren Newhauser set out to begin the long awaited exterior restoration of the the Milw Rd Dynamometer car. We planned to spend the day doing a small but complete test of sandblasting and painting on the roof in order to work out any issues/problems before tackling the entire roof. Under the supervision of Coach Dept Curator Paul Cronin, we used his Clemco industrial sandblaster to blast a part of the roof using 40/80 and 10/20 grit crushed glass media in Yard 3. The sandblaster air was supplied by the Track Dept’s tow behind diesel compressor. Full safety gear was used including a positive pressure respirator safety helmet.

Warren went first to test the sandblasting before 10am - Photo courtesy of Warren Newhauser

The team gathered on the scaffold to examine the early sandblasting results - Photo by Jane Pomazal

The sandblaster worked very well on areas with paint, taking it down to the bare metal very quickly. Where the roof had rusted, it took longer - much longer - to clean up the rust. Each roof panel, about 30”x40”, took about 5 minutes to blast.

After blasting 5 panels and the A/C duct above them, our next step was to power wash the bare metal with water and a metal wash solution called Hold Tight (not the Justin Bieber song!!), recommended by AGSCO who supplies the blast media to IRM. Hold Tight cleans contaminants/debris from the freshly blasted metal and prevents flash rust for up to 5 days. This is necessary if blasting and painting can not be done in the same day. To do this we borrowed B&G Dept’s pressure washer/tank on a trailer arrangement and filled the tank with about 100 gals of softened water from the Diner per Dave Diamond’s recommendation. We pressured washed the blasted steel roof panels, but we could not get the pressure washer to draw the Hold Tight solution so it ended up flash rusting a bit. The pressure washing did, however, remove a LOT of debris from the freshly blasted metal though. We later found we didn’t have the required “chemical” tip for the wand that would draw the metal wash in.

To deal with the flash rust, we applied, by brush, a metal prep solution to dissolve the flash rust and provide paint adhesion.

Lastly, by late afternoon, we then sprayed the Master Series primer on the panels and duct with Paul’s HVLP paint gun. This paint requires 2 coats of primer and one topcoat, thus one more primer coat will be needed before topcoat.

It was near 5pm when Chuck Pomazal started applying primer - Photo by Warren Newhauser

Chuck P applying primer - Photo by Chuck Trabert

Another shot of Chuck P applying primer - Photo by Chuck Trabert

Quarter to 6pm the first section of the roof has one coat of primer - Photo by Chuck Trabert

Close-up of the primed section of Dynamometer roof - Photo by Warren Newhauser

Unexpected Issues/Problems/Lessons Learned:

During the day the blasted metal roof was so hot you couldn’t even put your hand on it even with gloves on. This caused us to wait until the sun went down a bit late afternoon before starting painting. Painting outside needs to be done early in the morning or later in the day if it’s exposed to the sun.

The 10/20 media pits the metal roof more than the 40/80 media does, but removes the rust faster.

In the past, we applied a roof sealants Permaflex and Vulkem (urethane rubber sealants which have lasted years) that are very difficult to remove with the sandblaster.

Rusted metal takes a lot more effort to blast clean than painted metal.

Pressure washing blasted metal removes a lot of debris in the metal.

Now that we have done a test, we know what needs to be done to take on the rest of the roof. Based on the current sandblasting rates it will likely require 8-12 hours more sandblasting, 2-3 hours power washing, 4 hours to apply primer coat #1, wait 4-24 hours to dry, 4 hours to apply primer coat #2, wait 4-24 hours to dry, then topcoat (4 hours).

Thanks to Paul Cronin and Dave Diamond for all your help.

We have lots of opportunities for volunteers to learning the restoration processes. Please reply in a comment to the blog if you are interested in helping.

Friday, April 24. 2015

Report from Brian LaKemper:On 4/12 Brian Patterson and I did work inspecting cars for the season and outlining needed repairs before cars go into service. Cody Z. from steam land assisted. All service cars except the Silver Train have been inspected and needed repairs noted and some repairs made. More work will be needed before the beginning of the coach train season.

Elsewhere on the property, Buzz was working on the turbine, JD and Cody were working on 1630's stoker, and CTA 4290 was getting its inspection.

While others took the rules test, I went back to work on 2612, with help from Phil from the steam department. With a lot of heat and mechanical persuasion, the rusted fittings finally came loose. Afterwards, I worked on the X-5000, changing an air hose, and other minor housekeeping. I also traced out a problem with Galt House's handbrake not applying, apparently at some point during it's travels, it was decided that the way to release the handbrake was to torch through the handbrake chains!

Rich, Greg, and Joe watch as Brian P. runs the controller and the machine spins engaging its many different contacts - Photo by Brian LaKemper

Frank, Joel, and an unidentified person discuss the new training machine - Photo by Brian LaKemper

Rich and Brian (almost out of sight) discuss the CTA controller - Photo by Brian LaKemper

On Sunday 4/19, I removed one of the torched chains from the Galt House for repair by our metal working experts in the steam shop, and took the removed pipe to the shop for inspection. Big thanks to the steam shop for fixing the chain. I also removed a leaking valve stem from one of the conductor's valves on the X-5000 and flipped the double wear gasket to attempt to solve the leak.

Elsewhere on the property: after the annual meeting, several volunteers gathered in the electric car shop to try out the L car maintenance trainer. Turns out to be a very effective way of entertaining volunteers.

In the steam shop, work was ongoing on 1630's tender and cab floor, in addition to work on 428's axle boxes. The hydraulic planer is functional at last, though it still needs fine tuning.

Report from Michael McCrarren:On Sunday 4/19, Brian Patterson dropped by and talked to Kevin Kriebs who was working on the lantern display. Except for some minor additions, the exhibit is ready to open.

The last two Sunday we opened the china exhibit to the public and have gotten very good reviews. People are amazed at the variety of china we have on display. They also love looking at the menus to see what was served. The exhibit will have a formal opening on May 2.

Brian Patterson dropped by and talked to Kevin K who was working on the lantern display - Photo by Michael McCraren

Saturday, April 4. 2015

Michael McCraren Reporting: On Saturday, March 28th, Buzz Morisette and Kevin Kriebs assembled the second cabinet for the lantern display.

Buzz working on the cabinet hardware - Photo by Michael McCraren

Kevin and Buzz installing locks - Photo by Michael McCraren

Buzz and Kevin attaching the cabinet to the wall in Exhibit Car 1 - Photo by Michael McCraren

The finished lantern display cases - Photo by Michael McCraren

The opening of the 1st Exhibit Car with the china display is scheduled for May 2. Previews maybe held in April depending on staffing. Work has begun on adding displays to the 2nd Exhibit Car.

Expanded display of Wabash china - Photo by Michael McCraren

The photo history of Union Station is complete - Photo by Michael McCraren

Work has started in Exhibit Car 2 laying out a photo history of Grand Central - Photo by Michael McCraren

On Sunday, March 29th, Michael Baksic and Ray Mormann continued their work in the Birmingham.

Brian LaKemper Reporting: The 556's brakes are completely reassembled and ready for an air test.

On Sunday, March 29th, I cut the final pipe to the correct length, threaded and installed it with the help of Cody Z. from the steam shop. The needed fittings to assemble it all were procured and installed. Thanks to the Steam Department and the Electric Car Department for all their help on this part of the project.

The completed piping - Photo by Brian LaKemper

The brake beam installed under 556 - Photo by Brian LaKemper

Another view of the installed brake beam - Photo by Brian LaKemper

Mark Hoffman finished priming the cleaned ceiling panels. Still a lot of work in the interior of the car.

Inside 556 in Fall 2014 - Photo by Brian LaKemper

The same view inside 556 as of March 29th - Photo by Brian LaKemper

Close-up of primed ceiling in 556 - Photo by Brian LaKemper

On Wednesday, April 1st, Brian Patterson and myself applied air to test the brakes. After receiving a replacement gasket from Rod Turner (Thanks Rod!), everything was leak free and the brakes worked as intended. Once the interior is finished, the car will be ready for operation.

Elsewhere on the property: the clutch was removed from the Joy #2, so it can be repaired. The L car team has mounted poles on the 2400s and are rapidly finishing them up. In steam land, work is progressing on machining 428's axle boxes, 1630's winter repairs, and clearing tell-tales on the Shay.

Friday, March 27. 2015

Michael McCraren Reporting: On Saturday, Michael McCraren, Paul Machette, Mark Gellman, Mark Hoffman and Brian LaKemper attended a train show in Davenport, IA. On the way back, Michael, Paul and Mark did some "research" on current passenger trains by taking some action shots of the California Zephyr and Southwest Chief passing through Mendota, IL. After all, someday these cars will be at IRM. They also visited the depot museum there.

On Sunday, more graphics and a few pictures were added to the china exhibit. The big news is that we have added 2 rare service plates to the display for opening and a third that will arrive in the summer. The two new plates that will be there at the opening are an Illinois Central service plate used on the Panama Limited and the Daylight Limited (the fore runner of the City of New Orleans) in the 1920's, and another service plate from the Golden Rocket. After World War 2, the Southern Pacific and Rock Island were planning a replacement for the Golden State called the Golden Rocket. The Rock Island had ordered the china and cars but before the train could be started the Southern Pacific backed out. The china and cars were using on the Golden State. We have obtained a service plate from that still born train. A third service plate will be coming this summer. A hint is that the plate is from a well known, upscale, private dining room that was best ever on the rails.

Illinois Central service plate - Photo by Michael McCraren

Service plate from the Golden Rocket - Photo by Michael McCraren

Other work inside the 1st Exhibit car includes the picture history of Union Station Chicago where progress continues with the hand built sign going up along with the pictures and the cabinet for the upcoming lantern display was completed. Buzz M. and Kevin K. did a nice job building the cabinet.

Work on the picture history of Union Station Chicago continues - Photo by Michael McCraren

The cabinet that will hold the lantern exhibit is completed - Photo by Michael McCraren

Brian LaKemper reporting: On March 22nd, Mark Hoffman, Brian Patterson, and Brian LaKemper worked on the 556 again. Mark did more interior sanding, followed by priming some of the ceiling panels.

The two Brians worked to replace the last missing components of the brake system; however, a minor setback meant that we had to fabricate two pipes instead of just one, as during the process of pulling off a fitting to use as a guide, an adjacent pipe was found to have severe corrosion issues. Many thanks to the steam shop for help, encouragement, and use of tools to make both replacements. One of the replacement pipes was installed under the car, the other will be installed once we acquire the remaining fitting to attach it. Slow but steady progress overall.

Elsewhere on the property, Joy #2 was over the electric car pit for removal of the torque converter and clutch assembly. By the end of work, the torque converter was out of the pit and on a cart; but the clutch was stubborn and could not be removed.

Work was being done on Michigan Electric 28, UP 428 was having an axlebox set up for machining, and other projects were ongoing.

Wednesday, March 18. 2015

This update from the Passenger Car Department was provided by Michael McCraren...

Mark Gellman and Michael McCraren have taken over the task of preparing the graphics for the railroad china display in the 1st Exhibit Car. On Sunday, March 15th, Michael's niece, Patrice Connelly, joined them to help with the mounting of the graphics.

Mark Gellman is spraying the backing with adhesive - Photo by Michael McCraren

Mark is placing the graphic on the backing - Photo by Michael McCraren

Here Mark is rolling the graphic flat - Photo by Michael McCraren

Mark is cutting the graphic off the larger backing sheet - Photo by Michael McCraren

Mark is lining up the t-square for the trim - Photo by Michael McCraren

Marking the cut - Photo by Michael McCraren

The finished graphics being test fitted on the wall - Photo by Michael McCraren

The finished pattern labels up for the Milwaukee Road Traveler artifacts - Photo by Michael McCraren

Work continued on a photo history of Union Station and Kevin Kriebs painted the north wall in the front of the 1st Exhibit Car. He also worked with Buzz Morrisette on the lantern display which will also go up in the 1st Exhibit Car.

In other news, Ray Mormann and Michael Baksic have been working on the Birmingham diner. Shelly Vanderschaegen and Michael B. are refinishing a window for the Ely.

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Comments

Bob Venditti about Working on the Orange and BrownSun, 09-24-2017 19:47Great to see this car being
restored. Living in Fla, it's
difficult to visit as often as I'd
like to. Looking forward to seeing
it in IC colors on my [...]

Kirk Warner about Painting the Orange on IC 3345Fri, 09-15-2017 21:03I saw the IC car today and the
paint looks wonderful. The car
will stand out in a train once it
it ready for service. Great job!

Matthew about The Painted LadyFri, 09-15-2017 13:33Hi there I just wanted to say I
really enjoyed working on this car
although you forgot to mention my
help on working on it.

Robert J about Working on the Orange and BrownWed, 09-13-2017 19:32My understanding is that when IC
painted equipment in the orange and
brown that yellow went on firsat as
the primer coat followed by orange
and brown. [...]

Kurt Schlieter about Painting the Orange on IC 3345Wed, 09-13-2017 17:01Look great, but you might want to
seriously consider getting a
pressurized paint pot. These hold 1
to 5 gallons of paint depending on
size. This would [...]

Mike G. about The dream, Believe It!Sun, 09-10-2017 09:11From the satellite view on Google
maps, that appears to be mostly
wooden trestle with one section of
iron truss bridge... which by
itself is probably [...]

Patrick about The dream, Believe It!Thu, 09-07-2017 20:27That might be a bit too much
bridge. Measuring it on Google Maps
makes it out to be around 102 feet.
Using the same tools, the UP bridge
at the river [...]

Roger Kramer about Working on the Orange and BrownTue, 09-05-2017 10:17Hi Matt We estimate the costs for
installing 100 amp 240 volt stand
by service would be between $2500
to $3000. Our shop is now
designated area of [...]

Matt Maloy about Working on the Orange and BrownMon, 09-04-2017 09:34@ Roger, how much would it cost to
get this 10oamp 240 service?
Because I think that would be a
worth-while investment if the
museum installed it.